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Ceramic mass

Ceramic mass
IPC classes for russian patent Ceramic mass (RU 2270178):
Another patents in same IPC classes:
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Method of improvement of clay raw molding and drying properties / 2264364
The invention is pertaining to production of ceramic materials on the basis of clay raw and may be used, for example, for manufacture of an ordinary and facial building bricks, tiles, lining ceramic tiles, etc. The technical result is improvement of the molding properties of a ceramic mass and so increasing of the raw bricks crack resistance at drying, provision of a capability of a faultless self-acting charging and transportations of the dried semi-product. The method of improvement of molding and drying properties of the clay raw provides for addition of a technological mineral additive representing a rock consisting predominantly from minerals with the developed skeleton- cavernous porosity, drying at the temperature of 200-250°C within 2-4 hours for opening of a porous space, a comminution up to the dimensions less than 1 mm, a uniform distribution along the mass volume with the subsequent souring of the ceramic mass at the temperature of 30-40°C for no less than 24 hours.
Method of manufacture of wall ceramic articles / 2266267
Proposed method includes grinding of clay component, introduction of foam glass grits at size of grains of 0.1-5.0 mm preliminarily treated with water-repellent agent till obtaining of smooth surface, moistening and plasticizing, molding blanks by semi-dry method, drying and burning. Molding mass contains components at the following ratio, mass-%: water-repellent foam glass grits, 5-70; the remainder being clay component. Amount of water-repellent agent ranges from 0.1 to 10% of mass of grits. Molding of blanks by semi-dry molding method is performed at specific pressure of 4 Mpa. Waterproofed grits may be of egg-shaped or spherical form.
Method of manufacture of wall ceramic articles / 2266267
Proposed method includes grinding of clay component, introduction of foam glass grits at size of grains of 0.1-5.0 mm preliminarily treated with water-repellent agent till obtaining of smooth surface, moistening and plasticizing, molding blanks by semi-dry method, drying and burning. Molding mass contains components at the following ratio, mass-%: water-repellent foam glass grits, 5-70; the remainder being clay component. Amount of water-repellent agent ranges from 0.1 to 10% of mass of grits. Molding of blanks by semi-dry molding method is performed at specific pressure of 4 Mpa. Waterproofed grits may be of egg-shaped or spherical form.
Method of manufacture of building light-yellow ceramics and its composition / 2266878
Proposed method includes preparation of mineral additive, mixing this additive with clay, plastic molding of articles and burning. Additive is prepared according to slip process by grinding the clarifying component of additive with clay in the amount of 8-10% of mass of clarifying component; grinding is performed in ball mill to residue on sieve 0088 not exceeding 2-3%; then, hardening finely-dispersed component of additive is introduced into suspension. Slip thus obtained has density of 1.70-1.72 g/cm3. Slip is mixed with clay; part of clay is preliminarily dried to moisture content of 6-8%. Ceramic mass thus obtained is subjected to homogenization and aging for at least 24 h; burning is performed at temperature of 1020-1030°C. Marl at size of particles lesser than 2 mm and content of limestone no less than 75 mass-% is used as clarifying component and wollastonite concentrate at size of particles lesser than 0.063 mm and content of wollastonite no less than 80 mass-% is used as hardening finely-dispersed component.

FIELD: building industry, in particular ceramic mass composition useful in production of facing brick, lining panels, etc.

SUBSTANCE: claimed mass contains (mass %) heat treated clay fusible raw materials with completely burned carbon and organic admixtures and wherein pyrite is completely converted to Fe2O3 83-85; carbon-containing refractory clay 8.5-10; and law calcium lignite ash 2.0-5; crushed glass 0.9-1.5; vermiculite expanded 0-1.25-grade sand 1.5-2.0; waste from chalk production containing 48-49 mass % of hydrated lime as plasticizer 0.1-0.5.

EFFECT: dry brick of increased strength due to improved homogenizing of mixture component without losses of end item frost-resistance.

4 ex, 2 tbl

 

The invention relates to the field of construction, namely, the composition of the ceramic material, and can be used for the production of facing bricks, slab stones, slabs for cladding basements and fireplaces.

The known composition of the ceramic material, are given in EN No. 2090528 IPC6From 04 To 14/10; 18/04, bull. No. 26, 1997 (see table 3, compounds No. 1, 2, 3) and comprising components in the following ratio, wt%:

loam 75-80
not burned waste of coal mining
or coal sections Moscow basin 7.5 to 17
aluminosilicate postcolony
sand to the size of 0.14-5 mm 5-8
sawdust (in excess of 100% by volume) 5-7

Along with the great advantages of mass there are also disadvantages, limiting the possibility of obtaining the brick and facing plates on its basis, specifically:

1. Low architectural appearance due to the formation of dark areas (spots) on the front surface of wall ceramics, due to supervivencia during the burnout of the impurities of coal, containing in the composition of the waste of coal mining, combustion of sawdust.

2. Makes it difficult for the plastic molding sche is of evich stones due to the presence of coarse fractions (>2 mm) aluminosilicate postclosing sand;

3. Insufficient strength for solid bricks (RSG=of 10.05-13,01 MPa), which makes it impossible to get the front perforated bricks with a mark not less than M100, M125.

4. Not enough high frost resistance (F=15-20 cycles) for the brick or facade tiles.

Known closest to the proposed composition of the composition of the ceramic mass, which is given in the ed. certificate. No. 2099307, IPC604 In 33/00, bull. No. 35 (see table 6 compositions of No. 4 and No. 5) and containing components when following their ratio, wt.%:

coaly clay a 21.5-41
the fusible clay or loam 40-60
aluminosilicate atomical containing:
ground marriage (pot) ceramic 1,3-1,5
ash nizkokaloriinaja brown coal 1,5-10
cullet a 3.2-3
vermiculite exfoliated sand FR. 2.5 mm (max) 4-4,2

the plasticizer (RRT) in excess of 100% of the mixture, or without him

Known composition has great advantages, specifically:

1. Enhanced decorative appearance of products by Golden Shine of the individual particles of expanded vermiculite sand with particle sizes max 2.5 mm;

2. High stre is here under the pressure of for compounds 4 and 5 (21-25 MPa);

3. Sufficient strength for facing (front) facade ceramics (>45 cycles);

4. Recycled coal ash - TES, the reserves of which are in gidrootvalov huge, for example, in the Moscow coal basin.

The main disadvantages of the known solutions are:

1. Insufficient architectural expression, because..:

1.1. In some products, on the front surface is observed nauglerozhivaniya the appearance of dark spots due to incomplete combustion of coal and other organic impurities contained in the composition of carbonaceous refractory clay and ashes from TPPs, including the combustion of plasticizer type the RRT and other organic;

1.2. Insufficient adhesion of large flakes of exfoliated vermiculite with the front surface of the product due to the presence of particles of the coarse fraction (2.5 mm), i.e. as operating or loading - particles partially fall away from the surface of products;

2. Not achieved a good degree of mixing (homogenization) in wet (wet method of processing carbonaceous clay with dense shale structure, which reduces the strength of the dried bricks of cement, including the homogeneity of the color of burnt bricks.

The task of the invention is to increase the strength of the dry brick semi-finished product for the odd increasing the degree of homogenization of the mixture of dry ingredients mixture and architectural expressiveness without losing the strength and hardiness of finished products.

To solve the problem in the composition of the ceramic material that includes fusible clay raw materials, carbonaceous refractory clay, nizkokalievym lignite ash, cullet, exfoliated vermiculite sand, plasticizer, carbonaceous clay and nizkokaloriinaja lignite ash taken termoobrabotannyj to the complete burning of the impurities of coal and organic impurities and to complete the transition of pyrite in Fe2O3, expanded vermiculite sand taken from fractions of no more than 1.25 mm, and as a plasticizer taken the waste production of chalk containing hydrated lime 48-49 wt.%, in the following ratio of all components, wt.%:

clay fusible raw materials 83-85
heat treated to a full burn
impurities of coal, organic impurities and up
complete transition of pyrite in Fe2About3:
a) carbonaceous refractory clay 8,5-10
b) nizkokaloriinaja lignite ash 2,0-5
cullet 0,9-1,5
exfoliated vermiculite sand fraction 1.25 mm 1,5-2
waste chalk,
containing CA(Oh)248-49 wt.% 0,1-0,5

Characteristic components of the ceramic material

In the experiment adopted local fusible clay and loam used for the production of perforated bricks and stones in brick factories in Tula region.

1. Clay raw materials.

1.1. Loam. In the annealed form has a light red color and strength of samples based on it 17-23 MPa (firing temperature of 1000 -1050°). Contains Al2O3within 11,64-11,8%, i.e. raw materials are acidic, low-melting (temperature fire resistance - 1250°). Is moderately plastic raw material (CP=of 12.6 and 12.7), but highly sensitive to drying (low crack resistance). Is not fusible up to 1250°C.

1.2. Fusible clay. In the annealed condition has a cream color. The tensile strength of the samples under compression, annealed (t.950-980° (C) - 42-46 MPa. The resistance 1250-1270°C. Stiff, refractory, which is insensitive to drying. In connection with the pyrite content (in terms of SO3more than 2%) in the composition of the ceramic material is introduced in a limited number within a 15 - 20%. The content of Al2About317-20%. In the experiment experience made fusible clay raw materials, containing 85% specified loam and 15 wt.% the clay.

2. Carbonaceous refractory clay (brown coal) - waste obog is the value of coal production in the Moscow coal mines (Tula region). Color : black, as is impregnated with fine particles of coal: after calcinations (full burning coal), has a white color and resistance 1370-1380°C refractory. Is viscoplasticity and not very sensitive to drying due to the presence in its composition of coal. The average content of Al2About3up to 25-30%. After heat treatment has a loosely-porous structure.

The chemical composition
The content of oxides wt.%
Kimovsk section (coaly clay)
SiO2 Al2O3 Fe2O3 MgO Na2O To2About TiO2 CaO SO3 PPP
42,53-49,20 14,20-37,36 3,07-4,75 1,20-1,26 0,14-0,22 2,36-2,71 and 0.61-0.68 1,39-4,12 0,4-0,68 16,77-33,87

3. Thermo-treated ash from the combustion of brown coal.

In the experiment adopted getrootalias nizkokaloriinaja ash from the combustion of brown coal in the Moscow basin. Meets the requirements of GOST 4810-78 for coal-Moscow basin. After heat treatment has a light on Angely color. Specific surface area of fly ash 300-400 m2/kg.

The chemical composition of lignite ash Moscow basin (heat-treated)
SiO2 Al2O3 Fe2O3 CaO MgO To2O Na2O SO3
46-56 23-39 5-17,2 2-5 0,2-2,4 0,2-1,0 1-0,7 0,2-1,6

4. Exfoliated vermiculite sand. GOST 12865-67 "exfoliated Vermiculite".

The raw material is vermiculite concentrate Kovdor Deposit. The chemical composition corresponds to the chemical formula (K2)Al2O3SiO6(Mg)6O20(OH)4. Exfoliated vermiculite after firing has a Golden color, size scaly particles from 0 to 10 mm bulk density from 180-200 kg/m3. Before application of exfoliated vermiculite with a bulk density of 200 kg/m3sifted through a sieve with the hole diameter of 1.25 mm sieve Residue decreases and again dopolnitelno screened on a sieve with a diameter of 1.25 mm Sieved through a sieve vermiculite sand has a bulk density 200-220 kg/m3. Thus, in the experimental part of the mass used vspec the config sand with a maximum particle size of 1.25 mm

5. Cullet. Adopted three types of cullet from steklotarnogo, transparent glass and arkles - hardened glass (waste cleanup steklorezov). The ratio by weight of 1:1:1. Stcloudti to grind in a ball mill to a specific surface of 200 m2/kg and adopted for implementation in the experiments.

6. Waste of chalk production.

The chemical composition in terms of mass of dry, wt.%: Caso3- 45,0-51; CA(Oh)2- 48-49; SO3- 1,2-5,8.

Bulk density in the dry state 700-800 kg/m3. Specific surface area of 150-200 m2/kg. Easily disperses in water. The color white. Currently partly used as plasticizing additive in cement mortar and sand mortar.

Implementation of the proposed composition of the ceramic mass

Example 1.

Previously manually grind (coarse crushing), and then on laboratory edge-runner mills, dry grinding dry carbonaceous shale patterns clay Kimovsk coal basin. Lumps of clay with a diameter of not more than 5 mm was mixed with dry brown coal ash in the ratio adopted in the recipe made of the ceramic material, with the addition of wt.% on PPP (loss on ignition). The ratio by weight shown in table 1.

Dry mix termoobrabotki in a muffle furnace at a temperature of 750-800°i.e. before full vyzhe Gania impurities of coal and other organic impurities, and to complete the transition of pyrite in Fe2About3.

Heat the mixture to grind and sifted through a sieve with a diameter of 2.5 mm, the Product is sieved powder was used in the experiments.

- Breakage of glass, consisting of combat window glass, transparent containers and arleta (hardened glass), taken by weight in the ratio of 1:1:1, grind in a laboratory ball mill to the powder (specific surface area 200 m2/kg);

- Expanded vermiculite sand sifted through a sieve with a cell diameter of not more than 1,25 mm

- Waste chalk production (sludge humidity 60%) was dried and sifted through a sieve with a diameter of cells 0,315 mm

All prepared powdered materials (except career clay raw materials) were dosed out by weight in the ratio shown in table 1.

Occasioanly dry materials (without clay raw materials) were placed in a twin-shaft (blade model) mixer. Clay raw materials in the mixer (temporarily, at the first stage of mixing) is not added, because it is similar in composition and degree of processing and composition prototype and, in addition, the degree of mixing depends only on the state of coaly clays, i.e. heat-treated or neuroablative she adopted in the composition of the molded mass.

Example 2.

The determination of the degree of homogenization by mixing all dry ingredients (to the ome wet clay fusible material), included in the proposed ceramic masses, carried out the laboratory-estimated.

Occasioanly the dry ingredients in example No. 1 were mixed in a twin-shaft paddle mixer - 5 minutes And determined the coefficient of heterogeneity (variability)vin %, according to methodology described in the literature (Eremin NF Processes and devices in the technology of building materials: Textbook. for universities on special. "Production of building products and structures" - M.: Higher school, 1986. - 280 S.: specifically s).

The value of Cvdetermined by experimental data (for individual samples mixed mixture)taken at six different points of the mixer, followed by calculation according to the formulas(1), (2).

where n is the concentration of a key component % (or the mass of the original mixture, adopted for mixing and in which all the components are taken in a predetermined ratio).

In this experiment n=100% (600 g).

i - the number of samples taken for analysis. In the experience of 6 samples (N0=6).

Nithe concentration (or mass %) of each sample of the six remaining on the sieve with the hole diameter of 1.25 mm Mass per sample = 100,

N - concentration (or mass %) of each sample of six passed through a sieve with the hole diameter of 1.25 mm

σ - the degree of mixing.

Thus, in the experiment the mixture of all powders conventionally adopted for DOHC nonentry (or two-phase system).

a) Component No. 1 (phase No. 1-Ni) - private residue on a sieve of 1.25 mm

Each of the six samples - Ni,%.

b) Component number 2 (phase No. 1-N) is the mass of each sample, six, passed through a sieve of 1.25 mm

Defining value σidentified and the coefficient Cvby the formula (2).

The value of Cvfor each batch was more than 4% for all the sample mass, which means a good degree of mixing (see Nferen C). If set to Cv=4-6% is the degree of homogenization is good. Data Cvfor each batch of mix is given in table No. 2.

Example 3.

To the dry mixture with a high degree of homogenization added shredded and oldservername fusible clay raw material with moisture content of 18%. After this addition the mixture was mixed for 5 minutes with simultaneous governanee mass prior to forming a humidity of 20%. Mixed lot of missed twice through a laboratory rollers with a gap of 2 mm

Of the plastic mass was molded samples of size 5×5×5 cm with a force equal to the specific pressure of 2.5 MPa. Was dried and annealed samples of all parties in the factory. The maximum drying temperature 75-80°C. the Duration of 72 hours.

After drying of the specimens (from each party) experienced the strength, and the second part of the batch of samples was annealed at a maximum temperature 990-1000�B0; C.

Annealed samples were tested visually for architectural expression (presence of dark spots, mildew, color and the presence of brilliance), as well as the strength and frost resistance.

The degree of defects (marriage) was determined by the relationship of the total surface from five samples (ΣS1), have a specific defect (dark spot or height, etc. that do not meet the requirements of GOST), to the total surface of all samples before drying (ΣS0) and was expressed in %

ΣS0=5×(25×6)=750 cm2

The data of test results are shown in table 2.

Adhesion (bond strength) of the particles of vermiculite 1.25 mm with the surface of the samples was determined by performing a sample from a height of one meter and the presence of the falling particles.

Example 4.

This experiment was repeated all experiments No. 1, 2, 3 for the manufacture of prototype samples, excluding pre-heat-treated carbonaceous refractory clay and ashes from TPPs, and with the exception of the composition of the mass of waste chalk production, and expanded vermiculite sand sowed through a sieve with the hole diameter 2.5 mm test Data are shown in table 2.

Comparing the data of the test results of the proposed composition of the ceramic mass and the mass of the part of the prototype, draw conclusions.

1. The strength of dry samples of ceramics led is ensured by 15-30%, that should explain a higher degree of homogenization of the mass and the best pre-grinding the heat-treated carbonaceous clay.

In the proposed mixture Withv=4-6 TC. The degree of hamonization good, and in the structure of the prototype Withv=6, 7-7,2 TC, the degree of hamonization satisfactory.

2. Increased architectural expression as:

- no dark spots supervivencia and white vysokoobrazovannyj on the surface of the annealed samples of products;

particles of expanded vermiculite provide good adhesion to the mass of ceramic bricks, as not separated in the fall of samples with a height of 1 meter, and provide a point of Golden sheen, as is the case in the samples of the prototype, and uniform over the entire surface;

- color brick light orange, uniform (similar to the color of apricot) with evenly Golden glitter over the entire surface of the products.

The goal is explained by the following physico-chemical processes and factors:

1. Increasing the strength of dry samples of ceramics is explained by the following:

1.1. In the mass of molded samples of ceramics no burnable additives (particles of coal), which reduce the strength not only of dry samples, but burned;

1.2. Reduced the size of the particles of expanded vermiculite sand and its mass number, to the which after drying reduces the strength, as the firing increased, because they are weak smoothly.

1.3. Greater homogenization of the mixture when mixing, because the heat-treated carbonaceous clay of thick slate turns into a loose gently crumbling to powder mass.

1.4. Increases the adhesion between the particles due to waste chalk.

2. The increase in architectural expression should explain the following:

2.1. In the mass there is no burnable additives, and therefore dark spots due to supervivencia.

2.2. Purchased light orange (apricot) color due to waste chalk and calcined ash, carbonaceous heat-treated clay.

2.3. Fine exfoliated vermiculite sand FR. 1.25 mm gives a uniform Golden tone, and ensuring the strength of the sintered ceramics and frost resistance is achieved fewer autosites and lack of burnable additives, as well as the introduction of additional flux (lime)contained in the waste production of chalk.

3. In coaly clays contain pyrite (FeS2), which promotes the formation of efflorescence. However, when the heat treatment FeS2burns and goes in Fe2O3that is positive for architectural type.

Technical and economic substantiation of the ceramic mass compared to the mass about which atipa.

1. Wall ceramic prototype (formulations # 4 and # 5) in the presence of carbonaceous clay and ' green ' ash TES designed for normal low-grade facade ceramics with high enough architectural views, and facing ceramics) from the proposed composition belongs to the highest category with the selling price is 2-3 times more expensive.

2. Mechanical cost of grinding and sieving of the heat-treated carbonaceous clay offset by the disposal of waste chalk.

3. Thermal processing of carbonaceous clay and ash TPP does not require heat, because heat treatment is carried out by combustion of coal contained in their composition, and hot air with a temperature of 700-800°taken from the camera of the beginning of the cooling zone of rotary kiln. This volume of air is excessive, especially in the summer. Such air is recommended to be disposed of at a specified heat treatment process. The heat treatment can be carried out on the hearth of the annular furnace at joint firing with brick, without heat.

4. Plasticizing additive - waste chalk production helps to reduce water consumption, but also increases the plasticity of the molding material and, consequently, reduce scrap "settled down", i.e. reduces the number of defects in the molding. These the actors in 1-4 allow you to get profit increase by 20-25%.

Ceramic material that includes fusible clay raw materials, carbonaceous refractory clay and nizkokalievym lignite ash, cullet, exfoliated vermiculite sand, plasticizer, characterized in that the carbonaceous refractory clay and nizkokaloriinaja lignite ash taken termoobrabotannyj to the complete burning of the impurities of coal and organic impurities and to complete the transition of pyrite in Fe2O3, expanded vermiculite sand taken from fractions of no more than 1.25 mm, and as a plasticizer taken the waste production of chalk containing hydrated lime 48-49 wt.%, in the following ratio of all components, wt.%:

Clay fusible raw materials 83-85
Heat treated to a full burn
impurities of coal, organic impurities and up
complete transition of pyrite in Fe2O3:
a) carbonaceous refractory clay 8,5-10
b) nizkokaloriinaja lignite ash 2,0-5
Cullet 0,9-1,5
Exfoliated vermiculite sand
factions 0-1,25 mm 1,5-2
Waste production of chalk,
containing hydrated lime 48-49 wt.% 0,1-0,5

 

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